LED curing lamp and method

ABSTRACT

A curing lamp apparatus mounts to a work surface with a suction cup. A base is mounted to the suction cup. A flexible neck extends from the base to the lamp head. The lamp head includes a lamp element with first and second UV light sources which emit UV light at different wavelengths. A control circuit is located in the base. A heat sink is provided on the lamp head including a conductive plate and projecting pins. A protective housing encloses the plate and pins. A timing circuit controls the light source for automatic shut off. External or internal power is provided for the control circuit.

CROSS-REFERENCE TO RELATED APPLICATION

This application claims the benefit from U.S. Provisional PatentApplication Ser. Nos. 61/310,465, filed Mar. 4, 2010, and 61/411,784,filed Nov. 9, 2010, the disclosures of which are hereby incorporatedherein by reference.

FIELD OF THE INVENTION

The present invention relates to curing lamps for curing repair materialused to repair cracks in windshields or other glass or plasticmaterials.

BACKGROUND OF THE INVENTION

When a windshield or other glass or plastic material becomes cracked, aresin or other repair material can be used to repair the crack. Variousrepair bridges or devices with resin injectors are known for applyingrepair resin to the crack including devices shown in U.S. Pat. Nos.5,565,217; 5,776,506; 6,139,300 and 6,302,670.

Often the repair material needs to be cured with an ultraviolet (UV)light source. Lamps including a UV light source are known which arepositioned adjacent to the windshield or other surface, close to thecrack to cure the repair material positioned in the crack. An examplelamp is shown in U.S. Pat. No. 7,131,752. A common wavelength for curinglamps is 365 nanometers.

There is a need for further improvements with respect to curing lamps.

SUMMARY OF THE INVENTION

The present invention includes a curing lamp apparatus for mounting to awork surface including a suction cup engageable with the work surface,and a base mounted to the suction cup. A lamp head extends from the baseand includes a lamp element. The lamp element includes a first UV lightsource emitting UV light at a first wavelength, and a second UV lightsource emitting UV light at a second wavelength.

A further aspect of the present invention relates to a curing lampapparatus for mounting to a work surface including a suction cupengageable with the work surface, and a base mounted to the suction cup.A lamp head extends from the base and includes a lamp element foremitting UV light. In one embodiment, a flexible neck connects the lamphead to the base. The flexible neck allows bending and rotation aboutthe neck.

In a further aspect, the lamp head includes a heat sink. In oneimplementation, the heat sink includes a plate and projecting pins. Ahousing surrounds the heat sink.

In a still further aspect, the lamp element includes a substrateincluding a plurality of dies which include LED emitting structures. Areflector mounts to the substrate. A lens covers the reflector.

Another aspect of the present invention relates to a method of repairinga structure comprising applying resin to a crack on a first side of thestructure to be repaired; and mounting a base of a lamp apparatus to asecond side of the structure, wherein the second side is opposite to thefirst side. The method further comprises directing UV light from a lampelement connected to the base through the structure to cause curing ofthe resin in the crack.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a first perspective view of a curing lamp in accordance withone embodiment of the present invention.

FIG. 2 is an opposite side perspective view of the curing lamp shown inFIG. 1.

FIG. 3 is another opposite side perspective view of the curing lampshown in FIG. 1.

FIG. 4 is a side view of the curing lamp of FIG. 1.

FIG. 5 is an opposite side view of the curing lamp of FIG. 4.

FIG. 6 is an end view of the curing lamp of FIG. 4.

FIG. 7 is an opposite end view of the curing lamp of FIG. 6.

FIG. 8 is a top view of the curing lamp of FIG. 4.

FIG. 9 is another perspective view of the curing lamp of FIG. 1, showingthe lamp head rotated relative to the base about the neck, and showingthe curing lamp mounted to a windshield being repaired.

FIG. 10 is an exploded bottom perspective view of the curing lamp ofFIG. 1.

FIG. 11 is an exploded top perspective view of the curing lamp of FIG.1.

FIG. 12 is a top perspective view of the top cover of the base.

FIG. 13 is a side view of the top cover of the base.

FIG. 14 is an end view of the top cover of the base.

FIG. 15 is a top perspective view of the bottom portion of the base.

FIG. 16 is a top view of the bottom portion of the base.

FIG. 17 is a side view of the bottom portion of the base.

FIG. 18 is an end view of the bottom portion of the base.

FIG. 19 is a perspective view of the lamp substrate.

FIG. 20 is a front view of the lamp substrate of FIG. 19.

FIG. 21 is an enlarged view of a portion of the lamp substrate of FIG.20.

FIG. 22 is an example use of the curing lamp on a windshield beingrepaired.

FIG. 23 is a first perspective view of another embodiment of a curinglamp in accordance with the present invention.

FIG. 24 is an opposite side perspective view of the curing lamp shown inFIG. 23.

FIG. 25 is another opposite side perspective view of the curing lampshown in FIG. 23.

FIG. 26 is a side view of the curing lamp of FIG. 23.

FIG. 27 is an opposite side view of the curing lamp of FIG. 26.

FIG. 28 is a top view of the curing lamp of FIG. 23.

FIG. 29 is an exploded top perspective view of the curing lamp of FIG.23.

FIG. 30 is an exploded bottom perspective view of the curing lamp ofFIG. 23.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

Referring now to FIGS. 1-21, a lamp apparatus 10 for curing repair resinin accordance with one preferred embodiment of the present invention isshown. Lamp apparatus 10 includes a base 12 including at least onesuction cup 14 used for mounting lamp apparatus 10 to a windshield orother surface to be repaired. Extending from base 12 is a neck 16terminating in a lamp head 18. Lamp head 18 includes a lamp element 20for emitting UV (ultraviolet) light on the windshield. The UV light isused to cure repair material positioned in a crack within thewindshield. FIG. 9 shows the lamp apparatus 10 mounted on a windshield100 adjacent a break 102.

Suction cup 14 secures base 12 to the windshield as desired by the user.Suction cup 14 defines a longitudinal axis 28. Suction cup 14 includes abottom 24 which creates a sealing surface with the windshield. Knobs 26allow for opposite sides of suction cup 14 to be pulled toward base 12.Such action is useful to mount suction cup 14 to the windshield. Suchaction is also useful to remove suction cup 14 from the windshield.

Base 12 includes a top cover 32 and a bottom portion 34 which form anenclosed housing. Airflow slots 36 are provided within base 12. Base 12includes the control circuitry for lamp apparatus 10. A switch 38 allowsfor user control from an exterior of base 12. Base 12 also includes apower connector 40 for connecting to an external power supply, or abattery charger. Disposed within base 12 is a rechargeable battery 42. APCB 44 with the control circuitry is also contained within base 12.Conductors extend from PCB 44 through neck 16 to lamp head 18 forcontrolling lamp element 20.

Neck 16 allows for relative movement between base 12 and lamp head 18.In the illustrated embodiment, neck 16 can be rotated about longitudinalaxis 48. Neck 16 can also be bent relative to axis 48. With suchflexibility, lamp head 18 can be placed into a variety of positionsrelative to base 12. Compare FIGS. 2 and 9 which show rotation of lamphead 18 relative to base 12. In one embodiment, neck 16 includesLoc-Line® fittings which allow for rotation of head 18, or bendingmovement, or both.

Lamp head 18 includes a housing 56 which holds lamp element 20. Lamphead 18 also includes a heat removal device, such as a heat sink 60, foruse in cooling lamp element 20. Heat sink 60 includes a base 62 andprojecting pins or rods 64. A heat sink housing 66 surrounds base 62 androds 64 to protect from damage, and to protect the user from any sharpedges. Heat sink housing 66 defines a cage around rods 64 to protect theheat sink and allow for airflow to contact the heat sink to promotecooling.

Lamp element 20 includes a substrate 76 or PCB 76 which includes aplurality of dies 78 which emit the desired UV light. The substrate 76includes tracings 80. Side notches 82 allow for substrate 76 to mounttogether with heat sink 60 with fasteners 88 into sockets 90 in heatsink base 62. A reflector 84 concentrates the light, and a protectivelens 86 covers reflector 84.

An array of dies 78 is provided on substrate 76. (See FIG. 21). Each dieemits light at a certain wavelength. In one embodiment, an array of fiverows of eight dies are provided. Three rows 280 emit light at 365nanometers. Two rows 282 emit light at 395 nanometers. In the exampleembodiment, the rows alternate. In other embodiments, all of the dies 78emit UV light at the same wavelength.

The preferred embodiment includes at least two dies which emit lighteach at a different wavelength. Both 365 and 395 nanometers wavelengthsare considered in the ultraviolet range. One advantage for providing UVlight at 395 nanometers is that lamp apparatus 10 can be used from anopposite side of the windshield of an automobile. Compare FIG. 9 to FIG.22. In FIG. 9, lamp apparatus 10 is shown on the same side of thewindshield 100 as break 102. As shown in FIG. 22, lamp apparatus 10 isshown on an opposite side of the windshield 100, from break 102. Repairbridge 104 is mounted to exterior surface 106 of windshield 100. Lampapparatus 10 is mounted to interior surface 108.

Windshield 100 includes an outer layer 110, a middle layer 112, and aninner layer 114. Typically, middle layer 112 is a plastic film layer. Inthe illustrated example, break 102 occurs within outer layer 110.Injector 116 of bridge 104 is a repair device used to apply repair resin120 to break 102. As shown, injector 116 includes a pressure port 124and a mechanical probe 126. Lamp apparatus 10 can be used on either sideof windshield 100. Lamp element 20 includes emission of light at 365nanometers which works with many resins to cause curing when used on thesame side as the break.

As noted, lamp element 20 also emits light at a wavelength differentfrom 365 nanometers. With such a construction, lamp apparatus 10 cancure resin through a windshield which includes polyvinylbuterol (PVB)treated to block UV light at 365 nanometers or other certain types ofsolar protective materials. The PVB layer (e.g., layer 112) tends toblock light at 365 nanometer wavelengths, but passes the noted 395nanometer wavelengths. The light blocking properties for layer 112 arebeneficial as it reduces sunlight damage to an automobile's interior.However, the light blocking properties of windshield 100 prevent the 365nanometer wavelengths from light source 20 of lamp apparatus 10 fromreaching the resin to be cured. The 395 nanometer wavelength emittedfrom lamp element 20 is able to pass through windshield 100 in order toreach the applied resin material to be cured in break 102.

By allowing lamp apparatus 10 to be mounted on an opposite side ofwindshield 100, more room is available for the repair technician toaccess break 102. Also, curing from the bottom of break 102 allows forthe resin to shrink into the crack as it cures.

The PCB 44 is equipped with a timer that is programmed to start whenswitch 38 is pushed and remain on for an appropriate length of curetime. In the example embodiment, five minutes is selected. The timershuts off the light automatically. When switch 38 is pushed and held induring the five minute cycle, the lamp element 20 shuts off, afterapproximately 5 seconds. The cycle is started over again when switch 38is pushed again. The input to the circuit of PCB 44 comes from twodifferent sources. One input is a rechargeable battery, such as an 11.1VDC lithium ion or lithium polymer battery. The second input is a barreltype DC receptacle jack 40 that can be accessed outside base 12 for anexternal battery source or a 12 VDC AC/DC converter. In the preferredembodiment, the circuit accepts 9-14 VDC and boosts it to approximately18.5 volts controlling the current output at 270 milliamps (MA). Jack 40is used to recharge the battery.

Referring now to FIGS. 10-21, additional details of lamp apparatus 10are shown. Suction cup 14 mounts to bottom portion 34 of base 12 withscrews 200 which pass through apertures 202 in bottom 34 into sockets204 of suction cup 14. Bottom portion 34 of base 12 further defines aside aperture 206 for switch 38. A second side aperture 208 in recess209 in bottom portion 34 aligns with power connector 40 mounted on PCB44. PCB 44 mounts with screws 210 which are received in sockets 212 inbottom portion 34 after passing through apertures 214.

Base 12 defines a pocket for holding battery 42 above PCB 44. Bottomportion 34 includes a front rib 220 and a rear rib 222 which captureends of battery 42. Side ribs 224, 226 include a middle channel 228. Topcover 32 includes a front tab 230 which is received in a slot 232 ofbottom portion 34. Top ribs 234, 236 with middle channels 237 cooperatewith side ribs 224, 226 for positioning of the battery. A fastener 238passes through aperture 240 of bottom portion 34 and into a socket 242of top cover 32. A front wall 244 of bottom portion 34 includes anaperture 246. Front aperture 246 receives an end of neck 16 and allowsfor electrical cables to pass out of base 12 and into neck 16 forpassage to lamp head 18.

Neck 16 includes a first connector 248, a female/male connector 250, amale/male connector 252, and a second connector 254. Both first andsecond connectors 248, 254 are threaded for threadably mounting to base12 and lamp head 18, respectively. Each of the elements of neck 16includes one of the mating ball and socket connection ends which allowfor three-dimensional bending movement, and rotation about the neck axis48. More elements can be added if a longer neck 16 is desired.

Lamp head 18 includes a bulkhead plate 260 with an aperture 262 forreceiving neck 16. Bulkhead plate 260 mounts with screws 266 throughapertures 268 into sockets 270 of base 62 of heat sink 60. Housing 56mounts with fasteners 280 through apertures 282 into sockets 272 also onbase 62 of heat sink 60.

Heat sink housing 66 includes a body 170, with an open bottom 172 with aprotective flange 174. Open ends 176 are provided on body 170. Sides 178connect bottom 172 to top 180. Sides include first openings 179. Top 180includes second openings 182.

Referring now to FIGS. 23-30, a lamp apparatus 310 for curing repairresin in accordance with another preferred embodiment of the presentinvention is shown. Lamp apparatus 310 is similar in many respects tolamp apparatus 10. Lamp apparatus 310 includes a base 312 including atleast one suction cup 314 used for mounting lamp apparatus 310 to awindshield or other surface to be repaired. Extending from base 312 is aflexible neck 316 terminating in a lamp head 318. Lamp head 318 includesa lamp element 320 for emitting UV light on the windshield. Lamp element320 emits light at least two wavelengths like lamp element 20.

Base 312 includes a top cover 332 and a bottom portion 334 which form anenclosed housing for battery 342. Battery 342 and base 312 have adifferent shape relative to base 12 and battery 42 noted above. Base 312closely surrounds battery 342 and the control circuitry.

Base 312 includes similar control circuitry for controlling lamp element320. A PCB 344 with a control circuit is contained within base 312.Bottom portion 334 of base 312 includes a side aperture 408 in a recess409 which aligns with a power connector 340 mounted on PCB 344. PCB 344also includes an indicator light 345. When battery power becomes low(under 9 volts), indicator light 345 comes on and remains on until thebattery is charged again.

Lamp head 318 includes a housing 356 which holds lamp element 320. Lamphead 318 also includes a heat sink 360 like heat sink 60 and a heat sinkhousing 366 to protect heat sink 360 from damage, and to protect theuser from any sharp edges. Heat sink housing 366 includes a body 380with various openings 382 to allow for airflow.

What is claimed is:
 1. A curing lamp apparatus for mounting to a worksurface comprising: a suction cup defining a first longitudinal axisperpendicular to a suction cup surface engageable with the work surface;a base mounted to the suction cup; a lamp head connected to the base,the lamp head including a lamp element, the element including a first UVlight source for emitting UV light at a first wavelength, the lampelement further including a second UV light source for emitting UV lightat a second wavelength different from the first wavelength.
 2. Thecuring lamp apparatus of claim 1, wherein the first wavelength isapproximately 365 nanometers, and wherein the second wavelength isapproximately 395 nanometers.
 3. The curing lamp apparatus of claim 1,further comprising a flexible neck extending between the base and thelamp head, wherein the flexible neck defines a second longitudinal axis,wherein the lamp head is moveable in two directions relative to thebase, wherein a first direction is defined rotationally about the secondlongitudinal axis, and wherein the second direction is definedtransversely relative to the second longitudinal axis.
 4. The curinglamp apparatus of claim 1, further comprising a heat sink mounted to thelamp head, wherein the heat sink includes a conductive plate andprojecting pins, and further comprising a protective housing enclosingthe plate and the pins.
 5. The curing lamp apparatus of claim 4, whereinthe protective housing includes a body having an open bottom with aprotective flange which surrounds at least a portion of the lampelement, open ends on opposite sides of the open bottom, side panelswith a first plurality of openings extending from the open bottom andthe open ends to a top panel, the top panel including a second pluralityof openings.
 6. The curing lamp apparatus of claim 1, wherein the baseincludes control circuitry for controlling the lamp element, the controlcircuitry including a timer, and a switch, wherein: the timer is startedfor a first period of time and activates the lamp element when theswitch is pushed; the lamp element is shut off when the switch is pushedand held for a second period of time during the first period of time. 7.The curing lamp apparatus of claim 1, wherein the base includes controlcircuitry and a battery, the base further including a recess, the recessincluding a power port and an indicator light for indicating low batterypower.
 8. A curing lamp apparatus for mounting to a work surfacecomprising: a suction cup defining a first longitudinal axisperpendicular to a suction cup surface engageable with the work surface;a base mounted to the suction cup; a lamp head including a lamp element,the lamp element including a light source for emitting UV light; aflexible neck connecting the lamp head to the base, the flexibledefining a second longitudinal axis, wherein the lamp head is moveableto the base in a first direction rotationally about the longitudinalaxis, and a second direction which is transverse to the secondlongitudinal axis; a heat sink mounted to the lamp head, wherein theheat sink includes a conductive plate and projecting pins, and aprotective housing enclosing the conductive plate and projecting pins.9. The curing lamp apparatus of claim 8, wherein the protective housingincludes a body having an open bottom with a protective flange whichsurrounds at least a portion of the lamp element, open ends on oppositesides of the open bottom, side panels with a first plurality of openingsextending from the open bottom and the open ends to a top panel, the toppanel including a second plurality of openings.
 10. The curing lampapparatus of claim 8, wherein the base includes control circuitry forcontrolling the lamp element, the control circuitry including a timer,and a switch, wherein: the timer is started for a first period of timeand activates the lamp element when the switch is pushed; the lampelement is shut off when the switch is pushed and held for a secondperiod of time during the first period of time.
 11. The curing lampapparatus of claim 8, wherein the base includes control circuitry and abattery, the base further including a recess, the recess including apower port and an indicator light for indicating low battery power.